Gasket for molding plastic optical elements



Sept. 15, 1970 D. R. REITERMAN GASKET FOR MOLDING PLASTIC OPTICAL ELEMENTS Filed Feb. 19. 1968 Z A A v V ,//A l M W E a 2 e w N. w

. 1NVENTOR.

United States are 3,528,135 GASKET FOR MOLDING PLASTIC OPTICAL ELEMENTS Donald R. Reiterman, Sierra Madre, Calif., assignor to Armorlite Lens Company, Inc., Burbank, Calif, a corporation of California Filed Feb. 19, 1968, Ser. No. 706,717 Int. Cl. B21]: 5/00 US. CI. 1839 Claims ABSTRACT OF THE DISCLOSURE upper surface of the ring secured to the lower mold member.

This invention relates to an improved mold assembly for molding plastic optical elements and features an improved elastomeric gasket for holding the mold members in vertically spaced relation and to an improved mode of supporting this gasket outwardly of but closely adjacent the rim edge of the optical surface of the lower mold member.

Molding optical elements with optically finished surfaces free of distortions and imperfections presents numerous vexatious pnoblems. Desirably, the two mold members are separated from one another by a peripheral resilient gasket member which adheres to the casting sufficiently to prevent premature separation of the casting from the mold components during cure. Additionally, it is of critical importance to maintain a fluid-tight seal at the periphery of the mold cavity at the junction of the gasket with the lower mold member. At least the upper seal must permit the escape of any excess quantity of the charge and the lower seal must safeguard against leakage of the charge as curing proceeds. It is also highly desirable that suitable means be provided for accurately centering the upper mold member concentrically of the lower mold member without introducing restraints interfering with movement of the members to accommodate shrinkage of the charge during curing.

Other problems associated with the molding of plastic elements involve the protection of the rigid lower mold member from damage during handling This member customarily is made of glass and its precision upper surface is provided with an optical finish. Since this member is normally reused many times, it is subject to frequent handling during assembly, disassembly, cleaning, inspection and other operations. Accordingly, the optical surface can be irreparably injured, as by chipping, and most likely to occur adjacent its rim edge.

It is, therefore, the purpose of the present invention to provide a mold assembly or device avoiding the foregoing and other disadvantages and shortcomings of the prior art. To this end, the lower mold member has firmly secured to its peripheral edge a thick-walled ring of rigid material having an accurately finished planar upper end. An elastomeric gasket ring especially designed for use with this mold member features an inwardly opening annular groove formed with a lip at its upper inner edge so shaped and disposed as to have continuous line contact with the upper end of this ring outwardly of but close to the rim of the optical surface. The flange or ire bead forming the lower side wall of the gasket groove preferably has a press fit over the lower end of the rigid ring and serves to hold the gasket snugly assembled to the rigid ring of the mold member with the aforementioned sealing lip pressed in firm resilient sealing contact with the upper end of this ring. The upper half of the gasket side wall has an axial height corresponding generally with the rim thickness of the mold cavity and the upper end of the gasket is beveled in such manner that the upper inner rim of the gasket ring has continuous line contact with the underside of the upper mold member. Castings having either toric or spherical surfaces can be cast using the mold components embodying the principles of this invention.

Another feature of the gasket is the provision of bosses distributed about the periphery of its upper edge outwardly of its sealing lip and having radial contact with the peripheral edge of the upper mold member to hold it accurately aligned with the lower mold member.

It is therefore a primary object of the invention to provide an improved mold device for use in molding plastic optical elements.

Another object of the invention is the provision of a molding device utilizing a resilient gasket ring for holding the mold members accurately spaced including improved means for providing continuous line contact between the gasket ring and the mold members at the upper and lower peripheral edges of an optical element undergoing molding therebetween.

Another object of the invention is the provision of an improved flexible gasket for use in holding a pair of mold members accurately spaced and cooperating therewith to form a fluid-tight mold cavity during curing while permitting any excess charge to escape by overflow and drain fully away from the mold assembly.

Another object of the invention is the provision of an improved elastomeric gasket for molding plastic optical elements and adapted to be assembled about a rigid ring secured to a mold member therefor and having an endless lip in resilient sealing contact with the rigid ring.

Another object of the invention is the provision of a mold member for use in molding plastic optical elements and featuring a rigid ring secured to its periphery and having a smooth end surface flush with the adjacent rim edge of the molding surface of the mold member.

Another object of the invention is the provision of a mold device utilizing a toric mold member provided with a rigid ring about its periphery and having its upper end located below the toric mold cavity surface and including a cooperating resilient gasket ring embracing the rigid ring with its interior side wall stressed to lie in sealing contact with that portion of the peirphery of the mold member projecting above the upper end of the rigid ring.

These and other more specific objects will app ar upon reading the following specifications and claims and upon considering in connection therewith the attached drawing to which they relate.

Referring now to the drawing in which a preferred embodiment of the invention is illustrated.

FIG. 1 is a top plan view with parts broken away of one preferred embodiment of the assembled molding device designed for use in molding a toric optical element;

FIG. 2 is a side elevational view of the molding device;

FIG. 3 is a cross-sectional view on an enlarged scale taken along the broken lines 33 on FIG. 1; and

FIG. 4 is a fragmentary cross-sectional view on an enlarged scale through the molding device charged with plastic and designed for use in casting spherical optical elements.

Referring initially more particularly to FIGS. 1, '2 and 3, there is shown an assembled molding device, designated generally 10, and embodying the principles of this invention. The invention mold device or assembly includes a rigid lower mold member 11 of relatively thick glass and an upper mold member 12 of any suitable material having either flexible or non-flexible characteristics, and an intervening flexible elastomeric gasket ring 13. The upper surface 15 of mold member 11 is provided with a precision optical finish of a desired toric contour extending from rim to rim thereof. An optical finish 16 is provided on the downwardly facing lower surface of upper mold member 12, it being noted that the diameter of the upper mold member 12 is substantially greater than the optically finished surface 15 of the lower member 11. As herein shown, upper mold member 12, as herein illustrated, is relatively thin and flexible, as is desirable if the center portion of the mold cavity 36 is of different thickness than the peripheral portions of the cavity. However, it will be understood that the upper mold member may be relatively thick and non-flexible where shrinkage during curing is small or presents no separation problem.

Closely embracing rim 17 of mold member 11 is a relatively thick-walled rigid reinforcing ring 18. The upper rim end 19 of ring 18 lies in a diametric plane spaced axially below the lowest portion of the rim edge of toric optical surface 15. Ring 18 is held firmly assembled to rim 17 by a bonding agent. As here shown. reinforcing ring 18 is formed of suitable metal but it will be understood that it may consist of suitable rigid non-metallic material such as a strong tough plastic material immune to the ingredients of the composition being cast.

Gasket ring 13 forming an important feature of the invention is molded in one piece from a suitable thermoplastic material, its major portions preferably being substantially of the same thickness. The lower end half of the ring is formed with an inwardly opening groove adapted to receive and have a firm seating engagement with the reinforcing ring 18. The upper side wall 26 of groove 25 is inclined acutely to end surface 19 of rigid ring 18 thereby providing a sharp-edged sealing lip 27 at the merger of the groove side Wall with the overlying interior side wall 28 of the gasket ring. Side wall 28 preferably has a circumference slightly less than juxtaposed surface of mold member 11. In consequence, gasket surface 28 snugly embraces and seals against the portion of the mold member periphery projecting above ring end 19. In some cases it is preferable that lip 27 seal against ring 18 slightly outwardly of the inner rim edge of this ring. Lip 27 is also held lightly but firmly pressed against end surface 19 of ring 18 by the annular bead 29, it being understood that bead 29 is so designed that it must be press-assembled against the lower end 30 of ring 18. Projecting outwardly from the gasket opposite bead 29 is an annular flange 31 which increases the effectiveness of bead 29 and facilitates assembly and disassembly of the gasket from mold member 11.

The upper end of the gasket ring is beveled along the contour clearly shown in FIG. 3 and its upper inner edge provides a sealing lip 38 having continuous line contact with the optical surface 16 of the upper mold member. As best appears from FIG. 4, the beleveled upper end surface of the gasket ring provides a sealing lip 38 having line contact with upper mold member 12 while permitting excess portions of the charge to drain away from beneath the upper mold member as it settles into seating and sealing engagement with sealing lip 38 following the charging operation.

The second illustrative embodiment shown in FIG. 4 differs in only minor respects from that described above in connection with FIGS. 1 to 3 and the same or analogous features are designated by the same reference characters distinguished by the addition of a prime. The principal difference is that lower mold member 11 is formed with a spherical optical surface 15' having its rim edge flush with the upper end 19 of bumper ring 18. Sealing lip 27 seals against the inner edge of end 19 immediately adjacent the merger of the latter with the edge of mold surface 15.

The mode of use of the described mold devices will be quite evident from th foregoing detailed description of two typical embodiments. Prior to assembly of the gasket ring to the lower mold member, the latter is thoroughly cleaned and checked for the presence of any imperfections in its optical surface or the presence of any foreign matter on that surface or on any exposed surface of reinforcing ring 18. The mold member can be handled safely and without risk of chipping or injuring its optical surface because of the protection afforded by bumper ring 18 and the convenience provided by the latter in handling and gripping the mold member. A gasket ring 13 selected for use in a particular molding operation is similarly cleaned, inspected and then assembled about ring 18. As the lower wall or bead 29 of the gasket is pressed over the lower end of the ring 18, sealing lip 27 is lightly preloaded against the upper end of the ring thereby safeguarding against the possibility of a portion of the charge escaping from the mold cavity between the exterior of ring 18 and the surface of groove 25. If a toric lower mold member 11 is being used surface 28 of the gasket has a snug fit with the adjacent periphery of the mold member and cooperates with lip 27 in providing a highly effective seal.

After the upper mold member 12 has been carefully cleaned and inspected, it is lowered against sealing lip 38 of the gasket, the accurate position of the mold member being assured by a plurality of positioning bosses or locators 40 or 40' integral with gasket ring 13 and distributed about the upper outer rim of the ring as is made clear in FIGS. 1, 2 and 3. The spacing between bosses 48 is ample to receive the tips of the operators fingers while gripping the peripheral rim of mold member 12. The assembled mold device is maintained closed until ready for charging to prevent the possibility of foreign matter entering the cavity or collecting on any of the cavity surfaces.

To charge the mold, the user grabs the rim of mold member 12 between his fingers and tilts one edge upwardly suificiently to receive a charging nozzle. A charge of plastic, preferably prethickened close to the gel point, is then introduced along with suflioient excess to assure complete filling of cavity 36. As the charging nozzle is withdrawn mold member 12 is lowered gently against the upper lip 38 of the gasket as excess portions of the charge escape past the lip and overflow. It is found that if the mold is charged with prethickened resin and then placed in an oven at say F., the charge expands thermally and gels Without shrinking sufficiently to draw in a bubble of air. In this manner void-free castings are produced with consistency.

The charged mold device is then subjected to curing in an oven in a manner well known to those skilled in this art. Differential shrinkage of the cavity charge occurs in those cases where the center portion of the cavity is of different thickness than the rim portions and is accommodated by the gasket ring 13 and by flexure of member 12. However, such flexure does not result in disrupting the seal of either of the sealing lips 27 or 38. Additionally, and importantly, the thin flexible nature of lips 27 and 38 as well as the upper half of the gasket ring as a whole readily accommodates shrinkage of the plastic charge without introducing stresses or strain in the charge of distortions in the surfaces in contact with either of the optical surfaces 15 and 16.

Following curing of the charge the finished optical element 42 is removed from the mold device in the usual manner. Normally gasket ring 13 is peeled away first following which the upper mold member 12 is detached. Thereafter, the optical element 42 is separated from lower member 11.

While the particular mold assembly for molding plastic optical elements herein shown and disclosed in detail is fully capable of attaining the objects and providing the advantages he-reinbefore stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as defined in the appended claims.

I claim:

1. In a device for molding a plastic optical element comprising upper and lower mold members provided with opposed optically finished surfaces facing one another, that improvement which comprises rigid ring means rigidly secured to the periphery of said lower mold member with its upper end in a predetermined position relative to the rim edge of the optically finished surface of said lower mold member, resilient gasket ring means embracing said rigid ring means and detachably supported thereby, said gasket ring means having an upright tubular wall overlying said rigid ring with its lower inner edge in continuous line contact with the upper end of said rigid ring means and with its upper inner rim edge in continuous contact with the optically finished surface on the lower side of said upper mold member along a line spaced inwardly from the periphery of said last mentioned surface.

2. A molding device as defined in claim 1 characterized in that the upper and lower ends of said rigid ring means are parallel to one another, said gasket ring means having an inwardly projecting bead along its lower rim positioned to engage beneath the lower end of said rigid ring means and hold said gasket ring means firmly in assembled position thereon with the lower inner rim edge of said upright tubular wall slightly preloaded in resilient contact with the upper end of said rigid ring means.

3. A molding device as defined in claim 2 characterized in that the lower end portion of said upright tubular wall overlying the upper end of said rigid ring means is inclined upwardly and outwardly to provide a shallow annular void of triangu ar cross-section thereby to facilitate and enhance the seal between the lower inner rim edge of said tubular wall and the upper end of said ring means.

4. A molding device as defined in claim 1 characterized in that the upper outer portion of said upright tubular wall includes boss means positioned to engage the peripheral edge of the upper mo d member and hold it properly centered in vertical alignment above the lower mold member.

5. A molding device as defined in claim 4 characterized in that said boss means has wide openings extending radially thereacross providing gaps through which the rim edge of the upper mold member can be grasped while assembling and disassembling the upper mold member.

6. A molding device as defined in claim 4 characterized in that said boss means comprises a plurality of low height bosses distributed about the outer upper rim of said upright tubular wall.

7. A molding device as defined in claim 4 characterized in that said upper mold member is formed of relatively thin flexible material capable of flexing toward the lower mold member in response to shrinkage of a plastic charge filling the cavity between the mold members as the plastic charge cures.

8. A molding device as defined in claim 1 characterized in that the optically finished surface of said lower mold member is toric in shape, the side wall of said lower mold member projecting upwardly above the upper end of said rigid ring means throughout the circumference thereof, and the inner surface of the said upright tubular gasket wall being sized to embrace the upwardly projecting periphery of said lower mold member in the assembled position thereof to provide a snug seal effective to exclude migration of the mold charge therebcneath.

9. A mold device as defined in claim 1 characterized in that the upper end of said rigid ring means has an annular planar surface located flush with the adjacent peripheral portion of said lower mold member.

10. A mold device as defined in claim 1 characterized in that the upper end of said rigid ring means has an annular planar surface located close to but on a level below at least portions of the adjacent peripheral portion of said lower mold member.

References Cited UNITED STATES PATENTS 2,431,927 12/ 1947 Fairbank. 3,056,166 10/1962 Weinberg. 3,211,811 10/1965 Lanman. 3,222,432 12/ 1965 Grandperret. 3,330,331 7/1967 Duckwall et a1. 3,331,102 7/ 1967 Mignen.

J. HOWARD FLINT, JR., Primary Examiner US. Cl. X.R. 249-187 

